Continuous structure forming method

ABSTRACT

A method of forming a continuous structure includes the steps of flowing a first liquid reactive resin forming material over a base surface, forming a first thin substantially uniform layer thereof and gelling the first layer. A second liquid resin forming material is flowed through an orifice under pressure forming a liquid stream thereof. The liquid stream is gelled to form a continuous filament with structural integrity as it advances toward the first gelled layer. The filament is contacted with the first layer and distributed thereover in a preselected pattern forming a porous non-woven filament blanket. A particulate solid material is distributed substantially uniformly over the filament blanket. A third liquid resin forming material is flowed over the blanket forming a second thin substantially uniform layer of the third liquid resin forming material and the layer is gelled. The resulting freshly formed structure is compressed and positioned in a final configuration while the structure is flexible and adhesive after which curing is completed. Also, apparatus forming the structure as well as the structure itself.

This application is a continuation-in-part of pending application Ser.No. 239,540, filed May 9, 1994, which in turn is a continuation-in-partof application Ser. No. 870,927, filed Apr. 20, 1992, now U.S. Pat. No.5,330,603, which in turn is a continuation-in-part of application Ser.No. 753,344, filed Aug. 30, 1991, now U.S. Pat. No. 5,145,282, which inturn is a continuation-in-part of application Ser. No. 521,442, filedMay 10, 1990, now U.S. Pat. No. 5,049,006, which in turn is acontinuation-in-part of application Ser. No. 417,501, filed Oct. 5,1989, now U.S. Pat. No. 4,955,760, which in turn is acontinuation-in-part of application Ser. No. 235,205, filed Aug. 23,1988, now U.S. Pat. No. 4,872,784.

This invention relates to a novel continuous structure forming methodand apparatus and to a new continuous structure produced thereby.

The inventions of the applicant's early patents listed above providenovel methods and apparatus to produce at a job site structures such asliners and pipe for the collection, storage and/or distribution of waterand other liquids. The apparatus employed, which normally is transportedto a job site, is complex and sophisticated requiring major capitalinvestment.

The invention of applicant's recent patent listed above, U.S. Pat. No.5,330,603, provides novel method and structure that can be produced witha minimum of machinery at the job site. Thus, the structure and methodof the invention can be employed efficiently and economically forpatching and for small jobs even at remote locations.

While the applicant's earlier patents mention the use of recycled orwaste materials as additives in structures, most efforts of others havebeen directed to separating the waste into its primary components andthe combining of similar materials into the same product again. Variousgovernmental and private agencies have provided incentives such assubsidies and grants in attempting to develop commercially feasibleproducts and procedures for recycling waste. To date, only very fewwaste materials are routinely recycled on an economical basis.

The structure produced with the method and apparatus described inapplicant's latest application listed above, Ser. No. 239,540, caninclude major proportions of recycled, waste or other materials whichare readily available at a job site. These structures are of highquality and may exhibit properties not usually found in products formedwith conventional ingredients.

The present invention provides a novel method, apparatus and structurewhich overcome the shortcomings of previous expedients. In addition, themethod, apparatus and structure provide features and advantages notfound in earlier technology.

A great variety of different structures of the invention can be producedmore easily and conveniently with the method and apparatus of thepresent invention. The method may be conducted by individuals with onlylimited mechanical skills and experience. Structures can be produced bysuch individuals safely and efficiently without supervision. Theconfiguration and composition of the structure can be changed easily.

The method of the invention can be modified to provide structures withvariations in physical dimensions, composition and surface appearance,etc. Even with such changes, uniform high quality can be maintainedwithout difficulty.

A novel method of the present invention for forming a continuousstructure includes the steps of flowing a first liquid reactive resinforming material over a base surface, Forming a first thin substantiallyuniform layer therefrom and gelling the first layer. A second liquidresin forming material is flowed through an orifice under pressure toform a liquid stream thereof. The liquid stream is gelled to form acontinuous filament with structural integrity as it advances toward thefirst layer. The filament is contacted with the first layer anddistributed thereover in a preselected pattern to form a porousnon-woven filament blanket.

Thereafter, a particulate solid additive material is distributedsubstantially uniformly over the filament blanket. A third liquid resinforming material is flowed over the blanket forming a second thinsubstantially uniform layer thereof which then is gelled. The resultingfreshly formed structure is compressed and positioned in a finalconfiguration while it is flexible and adhesive and the curing thereofis completed.

Advantageously, a continuous filament is formed which has a generallycircular, rectangular or oval cross section. Preferably, the continuousfilament has a central passage along its length. Also, the filament mayvary in cross section along its length.

The continuous filament is distributed over the first gelled layer tocompletely or partially cover the first layer in a preselected pattern.Also, it may be advantageous to distribute the filament in a preselectedvariable pattern. The pattern forming the non-woven porous blanket mayvary in density and/or thickness along its length and/or width asdesired.

The method of the invention may include preconditioning of raw materialprior to forming the first, second and/or third resin forming materialstherewith. Also, the use of a major proportion of the solid additiveparticles is desirable. In addition, air or an inert gas may beentrained within the structure during its formation.

Benefits and advantages of the novel method and apparatus of the presentinvention will be apparent from the following description and theaccompanying drawings in which:

FIG. 1 is a side view of one form of mobile structure forming apparatusof the present invention;

FIG. 2 is a fragmentary side view of another form of apparatus of theinvention;

FIG. 3 is an enlarged fragmentary side view of the apparatus shown inFIG. 1 during an early step in the method of the invention;

FIG. 4 is an enlarged fragmentary side view of the apparatus shown inFIG. 1 during an intermediate step in the method of the invention;

FIG. 5 is an enlarged fragmentary side view of the apparatus shown inFIG. 1 during a further step in the method of the invention;

FIG. 6 is an enlarged fragmentary side view of the apparatus shown inFIG. 1 during a later step in the method of the invention;

FIG. 7 is a greatly enlarged schematic illustration of a cross sectionof a filament formed with the apparatus of the invention;

FIG. 8 is a greatly enlarged schematic illustration of a cross sectionof a different filament formed with the apparatus of the invention;

FIG. 9 is a greatly enlarged schematic illustration of a cross sectionof another filament formed with the apparatus of the invention;

FIG. 10 is a greatly enlarged schematic illustration of a cross sectionof a further filament formed with the apparatus of the invention;

FIG. 11 is a greatly enlarged schematic illustration of a fragmentarylongitudinal section of a filament formed with the apparatus of theinvention;

FIG. 12 is a schematic illustration showing apparatus of the inventionin use in the field; and

FIG. 13 is a schematic illustration showing another apparatus of theinvention in use in the field.

As shown in FIG. 1 of the drawings, one form of novel mobile continuousstructure forming apparatus 11 of the present invention includes asupporting portion 12, a raw material supplying portion 13, a mixingportion 14, a matrix forming portion 15 and a control portion 16.

The supporting portion 12 of the structure forming apparatus 11 includesat least one base section 20. Carriage means 21 operatively associatedwith base section 20 includes at least one transverse axle assembly 22,and as shown in FIG. 1, two axle assemblies 22,23 with wheels 24,25mounted on free ends 26,27 thereof.

The raw material supplying portion 13 of the apparatus 11 includes aplurality of reservoirs 29,30,31 operatively connected with thesupporting portion 12. The reservoirs 29,30 are connected independentlywith the mixing portion 14 through flexible conduit means 32,33. The rawmaterial supplying portion advantageously also includes a gravity feedhopper 36 receiving material from reservoir 31 through conduit 34.Preferably, heating means 37 is disposed along the length of the conduitmeans 32,33.

The mixing portion 14 of the structure forming apparatus 11 of theinvention includes a mixing chamber 39 mounted on the base section 20. Arotatable mixing element 41 is disposed within the mixing chamber asshown in FIG. 1. The rotatable mixing element 41 advantageously iscentrally aligned within the mixing chamber 39.

The matrix forming portion 15 of the apparatus 11 includes first mixturedistributing means 43 adjacent a first outlet 44 of the mixing chamber39. The first mixture distributing means 43 includes a first elongatedbarrier member 45 disposed closely adjacent to a matrix forming paththrough the apparatus and substantially perpendicular thereto.

Advantageously, the barrier member 45 as shown is a pivotable elongatedblade member 46 inclined to the matrix forming path in the direction ofadvance. Plastic film dispensing means shown as film supply roll 47preferably is disposed adjacent the first barrier member 45.

The matrix forming portion 15 further includes filament distributingmeans 48 including an orifice 49 disposed below a second outlet 50 ofthe mixing chamber 39 and operatively connected thereto. Reciprocatingmeans 51 is associated with the distributing means 48.

Additive particle distributing means 52 is disposed subsequent to thefilament distributing means 48. Second mixture distributing means 53including a second elongated barrier member 54 shown as pivotableelongated blade member 55 is disposed below a third outlet 56 of themixing chamber 39. Advantageously, plastic film dispensing means shownas film supply roll 57 is disposed adjacent the second barrier member54.

The matrix forming portion 15 advantageously includes a shallow traymember 58 disposed below the outlets 44,50,56 of the mixing chamber 39and below the matrix forming path through the apparatus. Preferably, thetray member is disposed in an inclined plane. Advantageously, the traymember 58 is connected to base section 20 through pivot connectors 59 tosimplify orientation of the tray.

Pressure applying means 60 is disposed subsequent to the second mixturedistributing means 54. The pressure applying means 60 may include a belt61 extending along the matrix forming path and particularly cooperatingbelts 61,62 disposed above and below structure 65 with at least one ofthe belts being a pattern forming belt. Most advantageously, cooperatingbelts 61,62 extending along the matrix forming path are disposed inplanes substantially parallel to tray member 58.

Alternatively, or in addition, the pressure applying means 60 mayinclude at least one roller shown in FIG. 2 as opposed rollers 63,64disposed perpendicular to the matrix forming path and extending beyondedges of the structure. Roller 63 and/or 64 advantageously includes apatterned surface. A cutter member 66 (FIG. 1) may be located prior toor subsequent to the pressure applying means.

To produce high quality structures of the invention, it is importantthat all of the steps be carefully coordinated by control portion 16.The control portion 16 of the structure forming apparatus 11 of theinvention includes programmable memory means 67 and actuating means 68responsive thereto in combination with coordinating means 69 to controlthe operation of pumps, valves, drives, etc. Preferably, thecoordinating means includes a process controller 70 that initiateschanges in the flows of materials and speeds of drives to bringvariations therein back to the rates specified in the programs presentin the memory 67.

This coordination commonly is achieved through the transmission ofinformation such as digital pulses from the monitors and/or sensors atthe control components to the process controller 70. The operatinginformation is compared with the preselected programming parametersstored in the memory 67. If differences are detected, instructions fromthe controller change the operation of the components to restore thevarious operations to the preselected processing specifications.

To form a structure of the invention employing apparatus 11 as shown inFIG. 1, the design of the structure desired first is established. Then,the design parameters are programmed into the memory 67.

To start the operation of the apparatus 11, buttons and/or switches 71of a control panel 72 are depressed to activate the memory 67 and theother components of the control portion 16. The coordinating means 69energizes actuating means 68 in the preselected sequences of the programstored in the memory 67. This causes a liquid reactive resin formingmaterial to be advanced from a reservoir 29 through a conduit 32 intomixing chamber 39. Simultaneously, other minor ingredients e.g. colors,catalysts, etc. from reservoir 30 advance through conduit 33 into mixingchamber 39 and are mixed with the resin forming material advancingtherethrough by rotatable mixing element 41.

The resulting liquid mixture flows through a first mixing chamber outlet44 onto a base surface shown as a moving plastic film 74 being deliveredfrom roll 47. With first elongated barrier member 45 disposed closelyadjacent to the plastic film 74 and transversely across the widththereof (FIGS. 1 and 2), a pool 75 of the mixture collects behind thebarrier member.

As the coated plastic film advances under the first barrier member 45,excess mixture is removed and a thin substantially uniform layer 76 isretained on the film. After the layer has gelled, a second resin formingmaterial flows from outlet 50 of mixing chamber 39 through orifice 49under pressure to form a liquid stream 77 therefrom.

The liquid stream is permitted to gel to form a continuous filament 78with structural integrity as it advances toward the first layer 76moving thereunder on plastic film 74. Filament 78 is placed in contactwith the first layer and distributed thereover in a preselected pattern79 with reciprocating means 51 to form a non-woven porous filamentblanket 81.

Thereafter, a particulate solid additive material 82 which has beentransferred from reservoir 31 through conduit 34 to a gravity fed hopper36 is delivered onto the filament blanket 81 advancing thereunder. Theparticles are distributed substantially uniformly over the filamentblanket.

A third liquid resin forming material from mixing chamber 39 flowsthrough a third outlet 56 thereof over filament blanket 81 filling theinterstices between the filaments and forming a continuous layerthereover. With a second longitudinal barrier member 54 disposed closelyadjacent to the filament blanket and positioned transversely across theblanket, a pool 83 of the third mixture collects behind the barriermember.

Simultaneously with the advance of the coated structure under the secondbarrier member 54, a second plastic film 84 from a roll 57 is insertedbetween the structure and the barrier member so the major faces of thestructure are protected by the upper and lower films. As the coatedstructure advances under the second barrier member 54, the excessmixture is removed and a second thin substantially uniform layer 85 isretained on the structure and the second layer is allowed to gel.

The resulting structure is compressed by passing it between belts 61,62and/or rollers 63,64 to ensure that the components thereof bear tightlyagainst one another. This produces a dense structure with strong bondingbetween all components.

If it is desired to form a preslected patterned surface, the structureis passed into contact with a patterned belt 61 or roller 63 or acombination of belts 61,62 or rollers 63,64. Advantageously, a patternis formed on the surface by applying pressure for an extended period oftime. This may be accomplished by using cooperating belts 61,62 ofconsiderable length.

Since the filament blanket is formed in situ as an integrally formedcomponent of the structure, the bonding of the resin forming mixtureswith the filamentary mass is much stronger than would result with handbuilding methods in which the surfaces of pre-formed components havebecome desensitized by exposure to the atmosphere. Thus, the method ofthe invention allows the use of lesser quantities of resin formingmaterials to achieve equivalent structural properties.

The in situ formed filamentary pattern also may be utilized to inspectand/or monitor a structure internally. This may be accomplished throughthe use of signal transmitting materials in the formation of thefilament. In this way, the filament can function as an optical fiber toallow inspection internally both during the forming of the structure andthereafter when the structure is in use.

Similarly, if the filament includes an open central passage, amicro-miniature TV camera can be passed along the passage to monitor thestructure during and/or after fabrication. Other sensing components suchas lasers also can be employed for the same or other purposes.

The inclusion of upper and/or lower plastic films may facilitate theinstallation of novel structures of the invention under adverse weatherconditions or below water or other liquids. Also, the flowing of resinthrough film openings can provide adhesion of the structure to asubsurface (not shown).

The apparatus 86 shown in FIG. 2 is similar to apparatus 11 with theexception that plastic films are not disposed over the upper and lowermajor surfaces of the structure. Instead, the apparatus 86 includes astationary low friction temporary support surface 87 on which firstlayer 76 is formed. It is important that resin forming materials withrapid gelling and curing capability be utilized to ensure that thestructure will have structural integrity before being separated from thesupport surface 87.

Apparatus 86 also includes one or more rotatable wheels 88 (FIG. 2)preferably mounted on brackets (not shown) extending forwardly from thebase section 20. These wheels are oriented to press edges of a structure89 against a supporting surface such as the ground (not shown).Preferably, the wheels include hollow spoke members 90 which includepins or nails 91 with mechanisms (not shown) that drive the pin througha structure edge and into the underlying supporting surface to fix theposition of the structure.

FIGS. 3-6 show succeeding steps in the formation of one form of thestructure of the invention with apparatus 11. FIG. 3 shows the formationof the first layer 76, and FIG. 4 illustrates the formation of thefilament blanket 81. In FIG. 5, the solid additive particles 82 arebeing deposited on the filament blanket 81 and FIG. 6 shows theformation of second layer 85.

FIGS. 7-10 schematically illustrate different cross-sectional filamentconfigurations. FIG. 7 shows an oval, FIG. 8 a circle and FIG. 9 acircular configuration with a central passage. In FIG. 10, a generallyrectangular cross section is shown. FIG. 11 illustrates a fragmentarylongitudinal filament section which can be used to form an irregularpattern.

FIG. 12 illustrates the use of continuous structure forming apparatus ofthe invention in combination with a power shovel. The apparatus 93 issuspended from a bucket 94 of a shovel 92 movable along a bank of aditch 95. The apparatus lays continuous lengths of the structure of theinvention across the ditch from one bank to the other in an overlappingrelationship.

One end of each length of the structure is staked to the ditch bank andthe structure delivered from the apparatus which is disposed closely tothe ditch surface. This arrangement is especially useful under windyconditions.

FIG. 13 illustrates an end view of a structure forming apparatus 96straddling a narrow ditch 97 with banks 99 as a continuous structure 98is positioned longitudinally along the ditch.

The liquid reactive resin forming material employed to producestructures of the invention is selected to be capable of reaction toform the particular resin components desired in the final structure.Advantageously, the resin is a thermosetting resin such as apolyurethane or polyester. Should a polyurethane be desired, onereservoir may contain an isocyanate and another reservoir may contain apolyol. More commonly, the reservoirs may contain different partiallyformed materials which upon mixing interact to form the desiredpolyurethane. Examples of such partially formed materials includeso-called "A stage" resins and "B stage" resins.

Other resin forming systems may utilize a resin forming material in onereservoir and a catalyst in a second reservoir. Additional componentscan be premixed with one of the resin formers, e.g. fillers,reinforcements, colors and the like.

The particulate solid additive material advantageously is employed in aproportion significantly greater than that of the resin formingmaterial. The additive particles may be any of a wide variety ofinexpensive materials readily available at a particular job site.Natural mineral particulate materials such as sand and gravel normallyare available or can be produced simply by crushing rock at the site.

Also, materials such as waste or recycled materials which can beshredded or ground into particles of suitable size can be utilized.Particularly useful are particles formed by shredding or grindingdiscarded tires. Since the particles are encapsulated with the resinforming material and not saturated therewith, many different wastematerials may be employed.

The above description and the accompanying drawings show that thepresent invention provides a novel method, apparatus and structure whichovercome the shortcomings of previous expedients and in addition,provide features and advantages not found in earlier technology.

The structure produced with the method and apparatus of the inventioncan include major proportions of recycled, waste or other materialswhich are readily available at a job site. These structures are of highquality and may exhibit properties not usually found in products formedwith conventional ingredients.

The method of the invention may be conducted by individuals with onlylimited mechanical skills and experience to produce high qualitystructures safely and efficiently. The method can be modified to form avariety of different structures. Variations in configuration,composition, physical dimensions and surface appearance, etc. can beachieved easily. Even with such changes, uniformity and high quality canbe maintained without difficulty.

It will be apparent that various modifications can be made in theparticular method, apparatus and structure described in detail above andshown in the drawings within the scope of the present invention. Themethod steps, apparatus components and types of materials employed canbe changed to meet specific process and structural requirements. Forexample, the number and disposition of porous filament blankets andpatterns can be different. Also, particulate additives may beincorporated in the resin forming mixtures and preformed reinforcingmembers included in the structure.

These and other changes can be made in the method, apparatus andstructure of the invention provided the functioning and operationthereof are not adversely affected. Therefore, the scope of the presentinvention is to be limited only by the following claims.

What is claimed is:
 1. A method of forming a continuous structureincluding the steps of flowing a first liquid reactive resin formingmaterial over a base surface, forming a first thin substantially uniformlayer of said first resin forming material, gelling said first layer,flowing a second liquid resin forming material through an orifice underpressure, forming a liquid stream of said second resin forming material,gelling said liquid stream to form a continuous filament with structuralintegrity as it advances toward said first gelled layer, contacting saidfilament with said first layer, distributing said filament over saidfirst layer in a preselected pattern thereby forming a porous non-wovenfilament blanket, distributing a particulate solid materialsubstantially uniformly over said filament blanket, flowing a thirdliquid resin forming material over said blanket, forming a second thinsubstantially uniform layer of said third liquid resin forming material,gelling said second layer, compressing the resulting freshly formedstructure, positioning said compressed structure in a finalconfiguration while said structure is flexible and adhesive andthereafter completing curing thereof.
 2. A method of forming acontinuous structure according to claim 1 including the step ofdistributing a continuous filament with a generally circular crosssection over said first gelled layer.
 3. A method of forming acontinuous structure according to claim 1 including the step ofdistributing a continuous filament with a generally rectangular crosssection over said first gelled layer.
 4. A method of forming acontinuous structure according to claim 1 including the step ofdistributing a continuous filament with a generally oval cross sectionover said first gelled layer.
 5. A method of forming a continuousstructure according to claim 1 including the step of distributing acontinuous filament with a central passage along its length over saidfirst gelled layer.
 6. A method of forming a continuous structureaccording to claim 1 including the step of distributing a continuousfilament with a variable cross section along its length over said firstgelled layer.
 7. A method of forming a continuous structure according toclaim 1 including the step of distributing a continuous filament oversaid first gelled layer in a preselected variable pattern.
 8. A methodof forming a continuous structure according to claim 7 wherein saidvariable pattern varies in density.
 9. A method of forming a continuousstructure according to claim 7 wherein said variable pattern varies inthickness.
 10. A method of forming a continuous structure according toclaim 1 wherein said second liquid resin forming material is a signaltransmitting material.
 11. A method of forming a continuous structureaccording to claim 1 including the step of preconditioning raw materialsprior to flowing said first, second and third liquid resin formingmaterial.
 12. A method of forming a continuous structure according toclaim 1 including the step of distributing a sufficient amount of saidparticulate solid additive material over said filament blanket toprovide a major proportion thereof in said structure.
 13. A method offorming a continuous structure according to claim 1 including the stepof entraining air within at least one of said resin forming materials.14. A method of forming a continuous structure according to claim 1including the step of flowing said first liquid resin forming materialover a plastic film.
 15. A method of forming a continuous structureaccording to claim 14 including the step of continuously advancing saidplastic film.